Breuckmann eMobility GmbH develops innovative rotor casting technology called Zero Porosity Rotor (ZPR) for electric vehicle induction motors. ZPR uses laminar squeeze casting to produce rotors with zero porosity, allowing for superior mechanical properties, higher electrical conductivity, and maximum process stability compared to industry standard rotors. Key advantages of ZPR rotors include up to 12.5% higher maximum rotational speed, 35% higher electrical conductivity, and ability to withstand 25% higher circumferential bursting speeds. Breuckmann has partnerships for motor testing, slot geometry design, and received EU funding to develop high-speed motor concepts using its ZPR technology.

1. breuckmann eMobility GmbH
Dieselstraße 26
42579 Heiligenhaus
10th International Motors Workshop
September 16th, 2021
Zero Porosity Rotor®
Setting a New Industry Standard for induction motors in
electric vehicles
Peter Szilagyi
Co-Founder & CEO
breuckmann eMobility

2. Business Areas
Casting Technology
Core Competencies
1. Tool Design
2. Tool Manufacture
3. Die Casting > 1000°C
4. CNC Post-Processing
Breuckmann Group
Hungary Kft.
TECH Center
Poland
Key Facts
4 Locations in Europe
Annual Turnover > 25 mio. €
> 200 Employees
> 100 Years Business Activity
Annual Casting Quantity > 1000t
2
Headquarters
Operations
Operations

3. Rotors for State-Of-The-Art Motor Types
3
Asynchronous Motors
Free of Rare Earths
100% Recycling
Synchronous Motors
Use of Rare Earths
Costly / Barely applied Recycling Process
Vs

4. OEM – USA 2016
OEM – DE 2015
R 0,52 mm
TIER1 – USA 2018
R 0,38 mm
R 0,61 mm
Milestones in Rotor Casting
Open and closed slots
4

5. Freedom in Slot Design through Pioneering Innovation
5
R 0,38 mm
b r e u c k m a n n ‘ s Z e r o P o r o s i t y R o t o r ( Z P R ® ) :
• Through another pioneering R&D result in breuckmann‘s
rotor casting technology, we make a groundbreaking
freedom in slot design possible:
• Great advantage technical design for high-speed
concepts with enhanced rotational speed
• Significant reinforcement of endring stability, i.e.
through concepts like the pinetree-slot design
• CU-Beryllium for reinforcement of endring stability
• Special slot design for improvement of magnetic
properties

6. Zero Porosity in the Slots
Aluminium
Copper
6

7. Laminar Squeeze Casting Technology by Breuckmann
7
Consistant
Mould Filling
Casting with very
high Pressure
Next Generation
Casting
Laminar Squeeze Casting

8. Status Comparison of Casting Technologies
Area
Porosity
Tol (max)
381.3662
10.1323
5.0000
[mm²]
[%]
[%]
8
Area
Porosity
Tol (max)
262.5746
0.01
5.0000
[mm²]
[%]
[%]
Industry Standard Zero Porosity Rotor – ZPR®

9. Side A
0%
Porosity
Zero Porosity Rotor Aluminium - Results
Side B
0%
Porosity
9

10. Zero Porosity Rotor Copper – X-Ray Analysis
10
ZPR®
Side B
Industry Standard
Side A
X-Ray
Cross-Section

11. Zero Porosity Rotor - Advantages
Superior Mechanical Characteristics
+ 12,5 % max. rpm
11

12. 1. CT scan of end ring
Influence of Porosity on Mechanical Properties
3. FEM simulation
Results
n1 - small influence up to 15.000 rpm
n2 - 7,5 % higher nominal rpm
n3 - 12,5 % higher maximum rpm
12
2. Transfering of CT scan data into CAD models
A - No pores
B - Small internal pores
C - Large internal pores
D - Small external pores
E - Large external pore with smaller pores
+ 12,5 % max. rpm
201 m/s
Circumferential
Speed measured

13. Zero Porosity Rotor - Advantages
Higher Electrical Conductivity
13

14. Electrical Conductivity
Area
Porosity
Tol (max)
381.3662
10.1323
5.0000
[mm²]
[%]
[%]
14
Area
Porosity
Tol (max)
262.5746
0.01
5.0000
[mm²]
[%]
[%]
Industry Standard Zero Porosity Rotor – ZPR®
Conductivity
AL 25 - 28 MS/m
Cu < 50 MS/m
Conductivity
AL 35 MS/m
Cu >57,5 MS/m

15. Zero Porosity Rotor - Advantages
Maximum Process Stability
15

16. Process Stability
16
Automotive understanding
of Quality
Production-
progress
Expected
Quality
Zero Porosity Rotor – ZPR®
Production-
progress
Expected
Quality
Electric Motor
Production
Industry Standard

17. Zero Porosity Rotor - Overview
Advantages
Superior mechanical characteristics
+ 12,5 % max. rpm
Higher Electrical Conductivity
Maximum Process Stability
17

18. ZPR® - Rotor Comparison Cu and Cu-Alloy
Electrical Conductivity = 58 MS/m
Overspeed Tests at 15.000 rpm = 111 m/s (max. speed)
Elongation = 0,47 mm
Bursting Circumferential Speed = 153 m/s*
Copper Rotor Copper Alloy Rotor
Electrical Conductivity = 45-50 MS/m
Overspeed Tests at 15.000 rpm = 111 m/s (max. speed)
Elongation = <0,04 mm (not measurable)
Bursting Circumferential Speed = 191 m/s*
Results
1. Efficiency of Alloy Rotor only 0,3 % lower than pure copper
2. No measurable elongation for Copper Alloy Rotor
3. Copper Alloy Rotor allows for + 25% circumferential speed
*Burst Test conducted at 200°C und low Acceleration Ramp
18

19. Key Partners
19
Motor Testing
Slot Geometry
High Speed Concepts Financial Funding from the EU
This project has received funding from the European Union’s Horizon 2020
research and innovation programme under grant agreement No 806095

20. breuckmann eMobility GmbH
Dieselstraße 26
42579 Heiligenhaus
Rotation Moves Us All